Delcam and Zytek Enter Technology Partnership to Develop Engine Manufacture
Share:
Delcam has entered into a technology partnership with the Zytek Group, one of the world's leading specialists in automotive control systems, race engine design and development, powertrain development, and hybrid-electric vehicles, to develop novel machining strategies for motorsport engine manufacture, in particular for the finish machining of inlet and exhaust ports. The partnership follows the impressive results achieved by Zytek since it changed to Delcam's PowerMILL CAM system in 2004.
"Since we began using the Delcam software to program our five-axis machines, we have reduced our manufacturing times by more than half, with a typical reduction for port machining down from forty hours to fifteen hours," claimed John Manchester, Operations Director at Zytek. "Similarly, we have reduced the machining time for our barrel throttles by 60% and increased the accuracy of the match to the inlet ports."
"In addition, we have so much confidence in the software that we have been able to introduce overnight, lights-out machining," added Mr. Manchester. "Our shifts operate between 6.00am and 10.00pm during the week, which used to leave many hours of unproductive time overnight and during weekends. Now, we leave the machines to run longer jobs overnight, giving up to eight hours extra productive time each night."
"Despite these improvements, we know that we cannot afford to become complacent with the level of competition we face in the industry," he explained. "We will be working with Delcam to produce even greater productivity from our machines in the future."
"Zytek has an incredible record of success with many of the world's leading race teams," acknowledged Delcam's Marketing Manager Peter Dickin. "The experience and expertise of its staff will provide valuable input to our development teams. In addition, their feedback on our new CAM strategies will provide further assurance that our programs work as well on the shop floor as they do on the computer."
While the main focus of the partnership will be on five-axis machining, joint projects will also be undertaken on high-speed three-axis machining. "All of the prototype components for our work on electric-powered vehicles have been programmed with the Delcam software, as have many of the unique parts for our sports cars," said Mr. Manchester. "Most of these parts are only produced in short runs because everything changes so quickly. We need to further develop our high-speed machining capabilities to ensure that our response times are kept to the minimum."
Zytek added PowerMILL to the facilities at its manufacturing centre in Repton, Derbyshire, following the award of a three-year contract to the company to supply all the engines and electric gear-shift systems for the A1GP World Cup of Motorsport race series. Unlike most other motorsport competitions, for A1GP, each team must have exactly the same engine and keep to the same design throughout the season. The change from short-run, or even one-off, production to the manufacture of around 60 identical engines necessitated a significant change in Zytek's production methods.
"We undertook a major investment in all areas of our manufacturing after winning the A1GP contract," remembered Mr. Manchester. "The addition of the Delcam software was an important part of that investment and one that has produced some of the best returns."
Zytek was founded in 1982 to develop and manufacture innovative electronic technologies for the exacting world of motor racing. The company has been responsible for many race-winning innovations, including the first digital engine management system for Formula One. Although best known for its success on the racetrack, Zytek has also worked with some of the leading names in performance motoring, including Aston Martin, Jaguar, Rolls-Royce and Bentley. More recently, the company has moved into the development and integration of electric and hybrid powertrain systems for concept and production vehicles.
